PRIM-ROCK addresses process efficiency through a multifaceted strategy addressing industrial processes from input to output, supported by an ambitious digital framework and transversal supporting activities. In particular, advanced techniques for the pre-processing of the raw material will be deployed to enhance its efficiency according to the requirements of the process, supplemented by simulations and decision support systems to increase the operational limits of flexibility in the feedstock domain. Additionally, the process intensification component of the project will design, develop, and validate innovative and efficient processes, as well as optimizing the existing ones. The aim is to develop a portfolio of technologies to a higher resource efficiency and lower level of GHG emissions of extractive industries. The project will focus on improving the resource efficiency of the calcination and roasting processes, that are commonly used in the mineral and cement industries. To this end, process simulations in collaboration with AI data-driven models will be utilized and a digital twin for each process will be developed. Finally, waste reduction and re-utilization strategies will be investigated targeting to the real-time processes’ adjustment capabilities to feedstock changes and tighter processing control solutions. All these components will be supplemented by transversal supporting activities, such as technoeconomic assessment, LCA, standardization etc. The PRIM-ROCK solutions will be demonstrated in 3 different ASPIRE sectors, namely Minerals (magnesite, laterite), Cement (limestone) and Non-ferrous metals (sphalerite, chalcopyrite). The consortium is composed of 7 SMEs along with 6 RTDs, 3 universities and 5 large enterprises, working together to achieve over 30% resource efficiency enhancement in each use-case, 770ktCO2 averted, productivity increase in the range 9-16% and more that 1,360 new jobs by 2033.

The DESTINY project aims to realize a functional, green and energy saving, scalable and replicable solution, employing microwave energy for continuous material processing in energy intensive industries. The target is to develop and demonstrate a new concept of firing granular feedstock for materials transformation using full microwave heating as alternative and complement to the existing conventional production. The DESTINY system is conceived as cellular kilns in mobile modular plant, with significant advantages in terms of resource and energy efficiency, flexibility, replicability and scalability with reduced environmental footprint. The DESTINY concept will be proved in two demo sites located in Spain and Germany, covering high energy demanding sectors of strategic interest as Ceramic (Pigments), Cement (Calcined clay) and Steel (Sinter, Iron Pellets/DRI, ZnO), to validate the critical parameters of the developed technology in relevant environment (TRL 6). It will be implemented 2 feeding modules per demo site and 1 mobile microwave kiln module and product treatment. Influence of the DESTINY solutions in terms of stability, process efficiency and characteristics of raw materials, intermediate/sub/final products will be investigated to improve performance of the industrial processes addressed and guarantee the required quality of products. Numerical simulation tools will be used to drive the design and support the testing activities The industrialization and sustainability of DESTINY high temperature microwave technology will be assessed through the evaluation of relevant KPIs, with Life Cycle Methodologies. With the final aim of ensuring a large exploitation and market penetration for DESTINY, technology-based solutions business model, economic viability and replicability analysis will be conducted. For guaranteeing industrial transferability appropriate exploitation and dissemination activities have been defined during and even after the end of the project.

The 2DPLOY project aims to provide support to EIIs by assisting them in developing compelling proposals for the Innovation Fund. SINTEF, VITO, ASPIRE and RINA-CSM, as research partners of 2DPLOY consortium, have already identified and shortlisted five promising H2020 projects from industrial partners (CEINNMAT, EVONIK, OLEON) and VITO. The 2DEPLOY methodology will be tested starting with these 5 pilot projects, which will help establish and undergo the project's innovation pipeline. This pipeline consists of several key steps, including: 1) screening H2020 projects through a prequalification matrix and a 1-hour interview with an expert; and 2) an evaluation commission that aims to select only the most mature projects. 3) The chosen projects will then be able to participate in advanced masterclasses that cover six different topics related to the IF's key requirements, such as degree of innovation, scalability, potential for avoided GHG emissions, and technical and financial maturity. 4) Finally, 2DPLOY will offer personalized guidance and feedback to support the preparation of three sound proposals to be submitted to the IF. The 2DPLOY methodology will be constantly improved through a two-way learning strategy that involves collaborations and synergies with key industrial and EU stakeholders, such as the Innovation Fund, the Directorate-General for Climate Action, Processes4Planet, Clean Steel, Clean Hydrogen Joint Undertaking, Batt4EU, and Clean Energy Transition. The activities and achievements developed within the scope of 2DPLOY can then be replicated by relevant HE Partnerships, to accelerate the deployment of mature, promising and high-impact innovations that come out of R&I projects, maybe combined with other de-risk mechanisms that can encourage innovation owners to invest in these technologies and, thus, pave the way for the decarbonisation of EII with European innovative technology.

Growing demand for high quality iron ores and scrap as well as abandonment of carbon intensive sintering in the future require novel technological approaches for upgrading of low-grade iron ores and recycling of mill scale. TransZeroWaste will apply hydrometallurgy for mill scale de-oiling and use this iron-rich scrap equivalent to upgrade low-grade iron ores. For that, TransZeroWaste will develop low carbon technologies such as cold pelletising and briquetting, hot microwave pelletising, and magnet-supported hydrometallurgy from TRL 6 to TRL 8. The developed technologies will be transferable to further material flows such as dusts and sludges. On European level, the expected impact will be the potential upgrade of over 18 million t/a low-grade iron ore, up to 6 million t/a mill scale and 3 million t/a pellet sieving residue. Total impact of TransZeroWaste will include upgrading of 27 million t/a materials with low carbon technologies and avoiding of corresponding sinter plant carbon footprint of 4,3 – 9,9 MtCO2/a. Technological competences and know-how are owned by the participating partners from the applied research. They will be developed and transferred to the two industrial partners with 9 production sites. Thoroughly planned dissemination and exploitation activities will ensure effective implementation of technologies after project end. Life cycle assessment and economic evaluation will be performed; sustainable business models will be developed. Furthermore, a decision support platform for industrial users will be installed. In combination with workshops and trainings it will help to find and implement the best upgrading technology for various low-grade materials considering environmental and economic aspects. TransZeroWaste will serve as a vehicle for the transition of the European steel industry to the carbon free zero waste future.

JOULIA aims to develop two innovative electric-heating processes to maximize their flexibility, energy savings and RES integration into two mid-temperature manufacturing processes. To this end, induction and microwave technologies will be demonstrated in the rubber and plastic sector for rubber vulcanization (rubber production) and glue thermal activation (multilayer pipes production) respectively. In this vein, processes configuration will be optimised and monitored, using the developed digital models and process simulations to fine-tune the whole industrial process enabling their control, adaptability and cost optimization. Health and security requirements will be implemented supported by a predictive maintenance tool. Both contactless systems will be validated at TRL7, including technical and economic studies (TEA and LCA/LCC) using previously developed models. Additionally, JOULIA solutions' replicability potential will be assessed in other industrial sectors (food and ceramics), addressing future upscaling plans to be aligned with new market opportunities and stakeholder engagement. General public awareness of electrified technologies will be improved while new business models and training materials will be developed. JOULIA will contribute to decarbonizing a sector that heavily depends on fossil fuel combustion, trying to maximize its energy efficiency, sustainability and economic benefits, improving European industries competitiveness and supporting their clean energy transition. To achieve these objectives, JOULIA's consortium consists of 16 partners from 7 EU countries, with diversified expertise and knowledge of the addressed processes and access to the required lab and pilot infrastructure. At the end of the project, JOULIA will increase the resilience and security of European industrial, as well as minimize its dependence on imported fossil fuels.